ALUMINIUM CASTING & MACHINING · WEDNESBURY, UK

From concept to production. One trusted partner for every component.

Alucast’s strength is not simply the number of casting processes it offers.
It is the ability to combine process choice, engineering expertise, manufacturing capability, quality assurance and supply-chain responsibility to deliver the right solution for each component.

Our core competencies provide customers with a single, technically capable partner from initial concept through to the finished component.

Request a quote → Talk to our engineers
/ WHY ALUCAST

Buyers don't want promises. They want evidence.

From initial concept to production-ready components, we deliver across high-pressure, gravity, low-pressure die casting and sand casting, with in-house CNC machining to complete the process. Precision engineered. Right first time. Delivered on time.

Our story →
01 / UNIQUE

The only UK foundry operating all four aluminium casting processes on a single site.

02 / CERTIFIED

IATF 16949:2016 & ISO 9001:2015 certified - automotive-grade quality across every sector.

03 / TRUSTED

Gold Kitemark - recognised among the best employers of engineering apprentices.

04 / AWARDED

Manufacturer of the Year (2012), Component of the Year, Manufacturing Company of the Year.

05 / INVESTED

Over £2m invested in 2024: new 800-tonne HPDC machine, six CNC machines, 120+ workforce.

06 / PROPRIETARY

Alu-HP1 alloy - lightweight, with SG Iron 420:12 mechanical performance.

07 / SIMULATED

Magmasoft casting simulation: design issues resolved before tooling, not after.

08 / INTEGRATED

One supplier, fully machined components - no managing multiple sub-contractors.

09 / GLOBAL

More than one third of production exported - internationally competitive from a UK base.

/ OUR CASTING PROCESSES

Whatever your volume, geometry or application - we have the process.

And the expertise to advise on the right one. Explore each route, or talk to our engineers.

HPDC · 01HIGH PRESSURE

High Pressure Die Casting

High volume, tight tolerances, fast cycle times - on our 800-tonne machine.
GDC · 02PERMANENT MOULD

Gravity Die Casting

Medium volume, superior surface finish, structural integrity.
LPDC · 03LOW PRESSURE

Low Pressure Die Casting

Complex shapes, superior mechanical properties.
SC · 04

Sand Casting

Prototype through to production.
CNC · 05

Machining

25 machines. Fully finished, one supplier.
ALL →

Compare Processes

Not sure which? We'll advise.

/ WHAT SETS US APART

Alucast’s five core competencies.

Our four casting processes showcase what we can do. Our core competencies demonstrate who we are, what we stand for, and the values that drive our business.

01

Technical capability

Four casting technologies. Engineering expertise. Integrated machining.

02

Quality & assurance

Controlled processes. In-house inspection. Measurable performance.

03

Track record & stability

Experience. Investment. Long-term capability.

04

Delivery & service

One partner. One technical team. One point of responsibility.

05

Sustainability

Efficient manufacturing. Responsible resource use. Continuous improvement.

01 - TECHNICAL CAPABILITY

The right process for the right component.

Alucast provides customers with genuine manufacturing choice through a broad range of aluminium casting technologies:

This breadth enables Alucast to assess the volume, geometry, material, performance requirements and commercial objectives of each component and identify the most appropriate manufacturing route.

Importantly, we do not believe the component should be designed around the limitations of a particular process.

We select the process around the component.

Looking down the Alucast foundry floor, crates of castings lining the aisle

Front-end design assistance

Good casting starts long before metal reaches the mould.

Our technical team can work with your engineering team to carry out an early-stage Design for Manufacture (DFM) review, helping identify potential casting and manufacturing issues while changes are still relatively straightforward to make.

Our team helps assess complex aluminium components, looking at areas including:

  • Draft and mould release
  • Wall thickness and geometry
  • Metal flow and thermal balance
  • Potential porosity
  • Feed paths and solidification
  • Tooling and manufacturing considerations
  • Machining requirements and datums

We also carry out initial casting simulation to identify areas where metal could become isolated during solidification - highlighting potential porosity risks before the component reaches production.

We don’t just tell you a component can be cast - we help identify and address potential issues before production begins.

An engineer reviewing a component drawing at a workstation in the metrology office
A machinist loading an aluminium casting into a fixture

Integrated manufacturing capability

Our capability extends beyond casting.

With in-house machining, Alucast can manage the complete journey from casting through to finished machined component under one roof. This provides:

  • Reduced lead times
  • Less component handling and transportation
  • Reduced risk of damage or variation between suppliers
  • Improved communication between casting and machining teams
  • Faster resolution of technical issues
  • One point of technical and commercial accountability

Cast. Machine. Inspect. Deliver. One partner.

A ladle being worked through molten aluminium in a melting furnace

Metallurgical expertise

Alucast’s technical capability is underpinned by extensive aluminium alloy and metallurgical knowledge.

The ability to select and control appropriate alloys, supported by in-house metallurgical testing and technical expertise, gives customers greater confidence that material performance, casting integrity and application requirements are properly understood and controlled.

Technical capability is not just about what we can cast. It is about understanding why, how and where it should be cast.

/ INNOVATION

ALU-HP1, our advanced high-strength alloy.

At Alucast, we’ve developed ALU-HP1, an advanced high-strength alloy designed to revolutionise the transport sector. For decades, the industry has relied on SG Iron for its durability - but at the cost of extreme weight.

Our solution is simple but transformative: a proprietary alloy that matches the mechanical properties of SG Iron 420:12 while providing a lightweight, high-performance alternative.

Explore ALU-HP1 →
Strapped stacks of aluminium ingots, close up

Targeted weight reduction

Drive energy savings and cut greenhouse gas emissions by reducing carriage weight to suit track conditions.

VLR optimised

Specifically developed to help Very Light Rail (VLR) improve energy efficiency.

Design consolidation

We help customers streamline designs by combining welded fabricated assemblies into a single casting, eliminating the need for multiple components and costly assembly work.

02 - QUALITY & ASSURANCE

Quality built into the process.

For customers in demanding sectors such as automotive, aerospace and defence, manufacturing capability must be matched by robust quality systems.

Alucast’s quality framework provides customers with confidence that components are produced within controlled, documented and auditable processes. Key areas include:

  • IATF 16949 automotive quality management
  • ISO 9001 quality management
  • Appropriate sector-specific quality requirements
  • In-house X-ray inspection
  • In-house dye penetrant testing
  • Metallurgical and material verification
  • Process control and traceability
  • Measured and monitored defect performance
Aluminium castings glowing green under UV light during fluorescent penetrant inspection
IATF 16949:2016 certification markISO 9001:2015 certification mark

Data, not just claims

Quality performance should be demonstrated through evidence. That’s why we measure the indicators that matter - PPM defect rates, customer complaints, first-time-through performance and corrective-action response - as part of our customer assurance.

Our quality is measurable, monitored and built into every stage of the manufacturing process.

03 - TRACK RECORD & STABILITY

Experience you can build your supply chain around.

Foundry supply is a long-term relationship. Customers are not simply selecting a supplier; they are selecting a manufacturing partner capable of supporting their component throughout its development and production life. Alucast’s credibility is built through:

  • Established industry experience
  • Long-term customer relationships
  • Investment in people, technology and equipment
  • Continuous development of manufacturing capability
  • Expansion and improvement of facilities
  • Recognition within the manufacturing and casting sectors
  • Experience supplying technically demanding components
  • Supporting apprentices through all stages of learning

Our continued investment demonstrates that Alucast is focused not simply on today’s requirements, but on building the capability required for tomorrow’s manufacturing challenges.

The Alucast leadership team, three directors, outside the headquarters in Wednesbury

Financial and operational resilience

A foundry is a capital-intensive business. Customers therefore need confidence that their supplier has the financial, operational and technical stability to support programmes over the long term.

We don’t just manufacture today’s component. We invest in the capability to support its future.

04 - DELIVERY & SERVICE

One partner. One point of responsibility.

Technical capability only creates value when it translates into reliable delivery.

Alucast’s integrated model enables front-end engineering, casting, machining, inspection and production teams to work together rather than operating as disconnected suppliers. This provides customers with:

  • Reliable and measurable on-time delivery
  • Rapid response to engineering queries
  • Effective management of engineering and design changes
  • Faster problem solving
  • Direct communication with technical specialists
  • One accountable partner throughout the programme
A stillage of fresh aluminium castings in front of stacked ingots

The Alucast approach

When a technical issue arises, the customer should not have to determine whether the problem sits with the toolmaker, foundry, machining supplier or inspection provider.

There is one partner. One technical team. One point of responsibility.

05 - SUSTAINABILITY

Responsible manufacturing for the future.

Sustainability is increasingly an important part of supplier selection, particularly for global automotive and industrial customers. Our approach focuses on measurable manufacturing impact, including:

  • Aluminium recycling and scrap recovery
  • Efficient use of raw materials
  • Energy efficiency
  • Responsible energy sourcing
  • Reduction of waste
  • Environmental management systems
  • Opportunities to reduce transportation through an integrated single-site supply model
  • Continuous improvement in manufacturing efficiency

Our ISO 14001 accreditation provides further evidence of a structured approach to environmental management.

Close-up of rows of stacked aluminium ingots
ISO 14001 certification mark

Sustainability through integration

There is also an important connection between Alucast’s single-site model and sustainability. By combining casting, machining, inspection and other manufacturing activities within one integrated operation, customers can reduce unnecessary transportation, handling and duplicated processes.

Our manufacturing processes can mean a better environmental outcome.

/ ENGINEERED, NOT JUST POURED

Magmasoft simulation, before tooling.

We model fill and solidification in Magmasoft - resolving porosity and shrinkage risk at the cheapest point in the development cycle, long before a die is cut.

4
CASTING PROCESSES
25
CNC MACHINES
120+
PEOPLE
1967
ESTABLISHED
MAGMASOFT
Aerial view of Alucast Ltd, Western Way, Wednesbury
WESTERN WAY · WEDNESBURY · WS10 7BW
/ A HISTORY OF DELIVERING

Established 1967, in the heart of the Black Country.

Alucast has spent decades proving what British aluminium casting can achieve. We've survived recessions, invested through downturns and built one of the strongest order books in our history.

We're not going anywhere - and neither are the standards we hold ourselves to.

Our story →
/ SECTORS SERVED

Precision aluminium casting for every demanding industrial sector.

IATF 16949 certified for automotive. JOSCAR registered for defence. Trusted across hydraulic, aerospace, rail and energy applications.

01

Automotive

Engine components, transmission housings, structural brackets and EV drivetrain parts - to IATF 16949 automotive-grade quality.

02

Aerospace

Precision aluminium castings where structural integrity and material consistency are non-negotiable.

03

Hydraulic & Fluid Power

High-integrity pressure-rated housings and manifolds engineered for leak-free performance from cast to finished part.

04

Defence & MOD

JOSCAR-registered. A proven, audited supply chain trusted by UK defence and government procurement.

05

Rail & Transport

Certified structural castings for rolling stock, trackside equipment and rail infrastructure applications.

06

Energy & Power

Robust aluminium castings for power generation, renewables and utilities - engineered for long service life.

07

Industrial & Agricultural

Versatile aluminium casting capability across fluid power, machine components and general engineering applications.

/ TRUSTED ACROSS EVERY INDUSTRIAL SECTOR
AUTOMOTIVE·AEROSPACE·HYDRAULIC·DEFENCE·RAIL·ENERGY·INDUSTRIAL·
The Alucast team gathered outside the headquarters in Wednesbury
/ THE ALUCAST DIFFERENCE

More than a casting supplier. A technical partner from concept to completion.

One partner. The right process. Complete confidence from concept to component.

Casting aluminium is one thing. Knowing how to turn a component requirement into the right manufacturing solution is another.

At Alucast, we bring together multiple casting processes, engineering expertise, machining and inspection capabilities to deliver the right solution for every component.

From selecting the most suitable process to developing, manufacturing and inspecting the finished component, we work alongside our customers at every stage - providing technical expertise, manufacturing capability and accountability under one roof.

Tell us what
you need.

Have a casting to quote, or a design to discuss? Your enquiry goes straight to the engineers who can help - we respond within 1 business day.

Request a quote → 0121 556 6111